Contents: Removal ↓ Installation ↓
Removal
Attention! The cylinder head must be removed on a cold engine.
Warning! If your radio has an anti-theft code, check that you have the connection codes before disconnecting the battery.
Caution! On models from 1993 onwards, the airbag system is disabled if the battery is disconnected for an extended period of time. If the airbag warning light comes on and remains on after the battery is reconnected, contact a specialist workshop to restore the system to working order.
1. Remove the ground cable from the battery.
2. Drain the coolant from the cylinder block and radiator.
3. Drain the engine oil and remove the oil filter.
4. Remove the throttle body, fuel injectors and fuel line.
5. Remove the intake manifold.
6. Remove the exhaust manifold.
7. Remove the timing belt, camshaft pulley and upper idler pulley.
8. Remove the rear timing belt cover.
9. Remove the camshafts and tappets.
10. Remove the generator and distributor.
11. Remove the power steering pump mounting bolt and move it to the side without disconnecting the hoses from it.
12. Label and disconnect any remaining pipes, hoses, cables and wires.
13. Working in the reverse order to that shown in the illustration, loosen the cylinder head mounting bolts 1/3 turn at each pass until the bolts are completely loose.
14. Remove the cylinder head.
Installation
1. The mating surfaces of the cylinder head and block must be completely clean. Use a hard plastic or wooden scraper to clean them. Be careful when cleaning, as the aluminum alloy is very easy to damage.
2. Check that carbon deposits do not get into the oil and water passages. This is especially important for the lubrication system, as carbon deposits can block the oil supply to engine components. If necessary, clean the passages, check the mating surfaces of the cylinder head and block for nicks, deep scratches and other damage. If the defects are small, they can be removed by mechanical processing, but if the defects are significant, the parts must be replaced.
3. Clean the bolt holes in the cylinder block. Screwing a bolt into an oil-filled hole can cause the block to burst due to hydraulic pressure.
4. Using a metal ruler and feeler gauge, check the flatness of the mating surfaces.
5. Install a new cylinder head gasket onto the dowel pins in the cylinder block.
6. Install the head onto the engine cylinder block.
7. Lubricate the threads of the cylinder head bolts with a thin layer of engine oil.
8. Install the cylinder head mounting bolts and tighten them to the specified torque in several stages in the sequence shown in the figure.
9. Further installation is carried out in the reverse order of removal.
10. Check and adjust valve clearances if necessary.
11. Fill the cooling system with coolant. Install a new oil filter and add engine oil.